F 350 4WD Super Duty V8-6.4L DSL Turbo (2008)
Removal
1. Remove the degas bottle assembly.
2. Remove the spring clip and disconnect the upper radiator hose quick connect coupling.
3. Disconnect the fuel cooler tube from the retainer on the power steering reservoir.
4. Remove the 2 bolts and position the power steering reservoir aside.
5. Loosen the charge air cooler (CAC) tube flex joint-to-turbocharger clamp and position the CAC tube aside.
6. Remove the cooling fan stator.
7. Disconnect the exhaust gas recirculation temperature (EGRT) sensor outlet electrical connector.
8. Disconnect the EGR valve coolant supply hose from the retainer and the EGR cooler.
9. Remove the EGR cooler coolant hose position retainer nut and the coolant hose position retainer.
10. Remove the EGR cooler upper nut and bolt.
11. Remove the EGR cooler upper stud.
12. Remove the EGR cooler lower 2 nuts, the 2 studs and the EGR cooler inlet gasket.
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Discard the 2 studs and the EGR cooler inlet gasket.
13. Remove the 3 nuts and separate the EGR cooler support clamps.
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Before removing the nuts, mark the location of the clamps on the support bracket.
14. Disconnect the EGR cooler coolant inlet hose and discard the clamp.
15. Position aside the EGR cooler and disconnect the EGR cooler coolant outlet hose.
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Discard the coolant outlet hose clamp.
16. Remove the EGR cooler and discard the outlet gasket.
17. Remove the power steering tube position retainers nut and position the power steering tubes aside.
18. Remove the 2 EGR cooler support bracket lower bolts and the stud bolt.
19. Remove the EGR cooler support bracket upper bolt and the EGR cooler support bracket.
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Remove and discard the 3 EGR cooler support clamps.
Installation
1. Position 3 new EGR cooler support clamps on the EGR cooler bracket.
2. Position the EGR cooler bracket and install the 3 bolts and the stud bolt finger-tight.
3. NOTE: Do not tighten the clamps for the EGR cooler at this time.
Position the EGR cooler and using a new clamp, connect the EGR cooler coolant outlet hose and loosely install the EGR cooler clamp nuts.
4. Using a new clamp, connect the EGR cooler coolant inlet hose and tighten the inlet and outlet hose clamps.
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Tighten to 4 Nm (35 lb-in).
5. Using a new EGR cooler outlet gasket, position the gasket and install the EGR cooler upper stud.
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Tighten to 31 Nm (23 lb-ft).
6. Install the EGR cooler upper nut and bolt finger-tight.
7. Using a new EGR cooler inlet gasket, install the lower gasket and the EGR cooler lower 2 studs.
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Tighten to 17 Nm (13 lb-ft).
8. Install the EGR cooler lower retaining nuts finger-tight.
9. NOTE: Make sure to locate the EGR cooler clamps at the marked locations on the support bracket.
Position the EGR cooler clamps and tighten the 3 clamp nuts.
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Tighten to 9 Nm (80 lb-in).
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Loosen the clamps 720 degrees.
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Tighten to 7 Nm (62 lb-in).
10. Tighten the EGR cooler support bracket lower 2 bolts.
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Tighten to 31 Nm (23 lb-ft).
11. Tighten the EGR cooler support bracket upper bolt and the lower stud bolt.
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Tighten to 31 Nm (23 lb-ft).
12. Position back the 2 power steering tube position retainers and install the nut.
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Tighten to 25 Nm (18 lb-ft).
13. Tighten the EGR cooler upper nut and bolt.
